Brassiere

ABSTRACT

A molded brassiere, a core assembly of a first layer of molded foam material laminated with a second layer of molded foam material, defining two breast cup regions and an intermediate bridge region. At least one layer of flexible material having non-stretch properties adjacent one of or intermediate of and laminated with the layers of molded foam material at the bridge region, and oriented so that across the bridge region parallel to the cup to cup direction the material is non-stretchable. A first and second layer of the fabric is laminated with the core assembly on the respective interior and exterior side and preferably encases the core assembly. A third layer joined at least to the first layer at or near the lowermost perimeter of the core assembly is wrapped over that perimeter and extends towards the remaining perimeter thereof.

The present invention relates to a brassiere that has improved comfort and in particular has reduced evident stitching.

A bra normally is manufactured from a number of pieces. These pieces are shaped into three dimensional forms, either by cutting and re-sewing or heat and pressure forming. The resultant pieces are then assembled into a bra by sewing.

Any raw edge of a garment such as a bra that is in contact with the skin of the wearer can become irritating after a long period of wearing the garment. The removal of such raw edges and seams is complicated when the three dimensional nature of the garment is taken into account.

It is therefore an object of the present invention to provide an improved brassiere that at least partly does not include sewn edges that present against the skin of the wearer and/or that will at least provide the public with a useful choice.

In a first aspect the present invention consists in a moulded brassiere including,

a core assembly of at least a first layer of moulded foam material preferably laminated with a second layer of moulded foam material, said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein at least one layer of flexible material having non-stretch properties is provided adjacent one of or intermediate of and laminated with said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable, and a first and second layer, each of at least a fabric material, is disposed on opposed sides of and each laminated with said core assembly on a respective interior and exterior side of said core assembly to preferably encase said core assembly, and a third layer joined at least to said first layer at or near the lower most perimeter of said core assembly, said third layer wrapped over the lower most perimeter and extending to or towards the remaining perimeter of said core assembly.

In a second aspect the present invention consists in a moulded brassiere including,

a core assembly of at least a first layer of moulded foam material preferably laminated with a second layer of moulded foam material, said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein at least one layer of flexible material having non-stretch properties is provided adjacent one of or intermediate of and laminated with said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable, and

a first and second layer, each of at least a fabric material, disposed on opposed sides of said core assembly on the respective interior and exterior sides of said core assembly, said first layer laminated to the interior side of said core assembly,

said second layer joined at its lower edge at the lower perimeter of the core, to said first layer and folded over to wrap around said core assembly to the exterior side of said core assembly,

the join between said third and second exterior layers located toward the bottom periphery of said moulded brassiere, having no raw edges or sewing presenting exteriorly.

Preferably there is an intermediate fabric layer between said core and at least one of said first and second layers of fabric that is/are laminated with said core.

Preferably said flexible material having non stretch properties is a woven fabric material with bidirectional non-stretch properties and is oriented such that the non stretch orientation extends across said bridge region parallel to the cup to cup direction of said core assembly.

Preferably said layer of flexible material having non stretch properties is captured intermediate of said first and second layer of moulded foam material.

Preferably said first and second layers of foam are coextensive with each other and both define the perimeter of the said core assembly.

Preferably said core assembly is of a shape defining only the breast cups, said bridge and preferably at least in part said shoulder straps, but not chest strap(s).

Preferably said chest straps extend outwardly from each side of said core assembly provided region of said moulded brassiere.

Preferably two underwire structures are provided intermediate of said first layer and said second layers of foam, one each adjacent the breast cup regions.

Preferably said first layer and said second layer of foam are laminated directly to each other save for said flexible material having non-stretch properties and said two underwire structures.

Preferably said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member.

Preferably said casing is a fabric material.

Preferably said casing is adhered to one or each of the facing surfaces of said first and second layers of foam by an adhesive material.

Preferably said casing is a tubular sock within which said rigid elongate member is located, the sock having closed distal ends.

Preferably said first layer and said foam layer or the foam layers are coextensive each other.

Preferably said second layer and said foam layer or the foam layers are coextensive each other.

In a further aspect the present invention consists in a moulded brassiere including,

a core assembly of at least a first layer of moulded foam material said core assembly defining two breast cup regions and an intermediate bridge region extending there between

and a first and second layer, each of at least a fabric material, disposed outside of said core assembly on the respective interior and exterior sides of said core assembly, said first layer laminated to the interior side of said core assembly,

said second layer joined at the interior side of core assembly at its lower edge at the lower perimeter of the core assembly to said core assembly (and preferably to the first layer) and folded over to wrap around said core assembly to the exterior side of core assembly.

In a second aspect the present invention consists in a method of manufacturing a moulded component assembly for a brassiere comprising or including:

affixing to a core of at least a first layer of moulded foam material (and preferably and a second layer of foam material) and preferably with which and/or between which there is sandwiched layer of flexible material having non stretch properties, a layer of fabric material at the inner side of the core and adjacent the lower perimeter of the core,

wrapping the layer of fabric material around at least part of the lower perimeter to the exterior of the core and affixing the layer to at least part of other perimeter regions of the core.

In a third aspect the present invention consists in a moulded brassiere, including

a core assembly comprising

a core layer defining two breast cup regions and having a proximal face and an opposed distal face and at least one upper edge and at least one lower edge, and a

a bridge region extending between the breast cup regions;

a distal layer, defining an upper edge and a lower edge, said distal layer extending from the distal face of the core assembly around at least part of the lower edge of the core assembly to the proximal face of the core assembly, said third fabric layer being folded over distally along its lower edge to form a distal flap, said distal flap being secured to the proximal face of the core assembly.

Preferably, the distal fabric layer may be comprised of at least one layer of moulded foam and at least one layer of fabric.

Preferably, the core layer may be composed of at least one layer of moulded foam and at least one layer of fabric.

Preferably, the distal fabric layer may extend from the distal flap, around the lower edge of the core assembly, across at least part of the distal face of the core assembly, and around the upper edge of the core assembly, to the proximal face of the core assembly.

Preferably, the distal fabric layer may be secured towards its upper edge to the proximal face of the core assembly towards its upper edge.

Preferably, the distal flap may be secured to the proximal face of the core assembly towards the lower edge of the core assembly.

Preferably, the distal flap may be secured to the proximal face of the core assembly towards the lower edge of the core assembly by means of ultrasonic welding.

Preferably, the distal fabric layer may be secured to the proximal face of the core assembly towards the upper edge of the core assembly by adhesive bonding.

Preferably, the distal fabric layer may be secured to the proximal face of the core assembly towards the upper edge of the core assembly by ultrasonic welding.

Preferably the core assembly may include an underwire assembly comprising at least one resiliently flexible curved elongate member.

The underwire assembly may be secured to the distal face of the core layer.

Preferably the underwire assembly may further comprise a sleeve disposed around the elongate member.

Preferably, the core assembly may include a chest strap member secured to the core layer outwardly of each breast cup region.

Preferably, the chest strap member may be secured to the core layer at a securing zone.

Preferably, the of the backs trap members may be secured to the core layer by sewing.

Preferably, the of the backs trap members may be secured to the core layer by ultrasonic bonding.

Preferably, each chest strap comprises at least a pair of ultrasonically bonded fabric layers each having an upper and lower edge.

Preferably, the fabric layers may be bonded to each other towards their lower edges.

Preferably, the lower edge of each of the pair of fabric layers of the chest strap may be folded in towards each other and bonded at their adjacent faces.

Preferably, each chest strap may include a resilient elongate strap.

The resilient elongate strap may be composed of natural or synthetic rubber.

Preferably, the core assembly may include a shoulder strap secured to the core layer towards its upper edge above each breast cup region.

Preferably, the distal fabric layer may overlap at least one of the securing zones where it extends from the proximal face of the core layer to the distal face of the core layer.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

Where reference herein is made to interior and exterior or similar terminology, it is meant to be understood to be in relation to the body of the wearer of the bra. For example the “interior” or “inner side” or “inner region” is a relative term to denote that an item is more proximate the face side of the bra that is more proximate to the body of the wearer than items of the bra that are more distal the body of the wearer. “Inner” does not mean “inner most” unless specified. This similarly applies to terms such as “outer” or “exterior”.

Any reference to the term “inner” or “interior” and “outer” or “exterior” as used in this specification is to be construed in accordance with the general definitions of the terms “proximal” and “distal” respectively.

By seamless is meant the bra is visibly substantially seamless, in that the edges of the bra are finished in a seamless way, for example by ultrasonic welding, or by folding the edge of an outer layer over and affixing it to an inner layer by a non-stitching means, or by some other means that is substantially without seams. Seams may however be found inside the bra structure where it is not externally visible, or in visibly less conspicuous externally at places such as the region where the shoulder strap is attached to a bra cup region, or the region where hook or eye tape is connected to the chest bands.

The term ‘comprising’ as used in this specification means ‘consisting at least in part of’, that is to say when interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present.

Preferred embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 shows a lamination of fabric layer with foam layer to form an assembly of laminated plies, one rectangular piece is cut from the assembly of laminated plies to form the exterior layer,

FIG. 2 shows that the foam layer of the exterior layer has been shaved so that an apex is formed at around the middle of each bra cup region,

FIG. 3 shows in cut away the underwire structure formed by wrapping a metallic underwire within a sock of fabric material closed at both ends by bar-tacking,

FIG. 4 shows the shaved exterior layer located between the upper and lower platens of a moulding machine, prior to moulding to impart three dimensional shape,

FIG. 5 shows the foam side of the moulded exterior layer being sprayed with adhesive by a spraying machine,

FIG. 6 shows from the inside, or what will be-come the inside surface of the moulded exterior layer, an underwire structure being positioned (e.g. by gluing) close to the lower perimeter of each bra cup region on the foam layer of the moulded exterior layer,

FIG. 7 shows a layer of flexible fabric material having non-stretch properties being positioned (e.g. by gluing) at the bridge region (i.e. between two bra cup regions) on the foam layer of the exterior layer,

FIG. 8 shows another layer of flexible fabric material (which is only slightly stretchable) having a general “W” shape being positioned (e.g. by gluing) along and over the underwire structures and across the bridge region,

FIG. 9 shows a piece of foam layer having a “U” shape being positioned (e.g. by gluing) above the W-shaped fabric material and along and over each underwire structure,

FIG. 10 shows the interior layer cut out from the assembly of laminated plies shown in FIG. 1 and shaved, located in between platens of a moulding machine, prior to being formed,

FIG. 11 shows lamination of the exterior layer with the interior layer by a moulding machine to form a core assembly, prior to the application of pressure and/or heat to form the lamination of the two layers, the underwire structures and layers of fabric material/foam pieces along the lower edge of each bra cup portion/at the bridge region becoming sandwiched between the exterior layer and the interior layer,

FIG. 12 shows the edges of the core assembly being trimmed,

FIG. 13 (A) shows shoulder straps (made from an assembly of pre-laminated plies having a foam layer sandwiched between two fabric layers) being attached to the core assembly by two small pieces of fabric tape having adhesive on one side, one end of the shoulder strap is attached to the core assembly by wrapping the small piece of fabric tape over the joint, the adhesive of which will then melt and provide bonding upon being heated up, e.g. by ironing, (B) shows the bra exterior side and bra interior side of the core assembly when seen from side on,

FIG. 14 shows moulding of the exterior most fabric ply by bullet moulds,

FIG. 15 shows the exterior most fabric ply after being moulded,

FIG. 16 shows the exterior most fabric ply positioned onto the exterior of the core assembly using needles, or pins,

FIG. 17 shows at (A) the exterior most fabric ply of each wing region of the bra cut out from a piece of cloth along the edges of a pre-shaped plastic ruler, and (B) the interior most fabric ply of each wing region of the bra cut out from a piece of fabric material which has adhesive on one side covered by protective paper, a pre-shaped plastic ruler is used to guide the cutting,

FIG. 18 shows the exterior most fabric ply of the wing portion being attached to the interior most fabric ply of the wing portion by sewing along the longest edge of each of these two plies,

FIG. 19 shows cutting along the joined edge of the two plies in FIG. 18 so that no stitching remains and at the same time sealing of the two plies together along a new edge using ultrasonic methods,

FIG. 20 shows fixing of adhesive tape onto rubber band,

FIG. 21 shows how the rubber band (having adhesive tape on one side of it) is then fixed on the exterior most fabric ply of the wing region along the edge joined with the interior most fabric ply,

FIG. 22 shows the exterior most fabric ply of the wing region and the interior most fabric ply of the wing portion located between two platens, prior to being laminated together with application of heat and/or pressure,

FIG. 23 shows each of the resultant laminated plies of the wing regions after being trimmed along the edge of the interior most fabric ply,

FIG. 24 shows in plan view the interior of the core assembly, the exterior most fabric ply edge is moved away so as not to be sewn at this point, each of the laminated plies of the wing region is located with its edge to be sewn pointing outward (i.e. toward the perimeter of the cup of the core assembly) the wing regions are then sewn on, (and the exterior most fabric ply, though not shown as it is on the other side of the core assembly)

FIG. 25 shows a similar view to that of FIG. 24, but from the other side (exterior side) of the core assembly, the exterior most fabric ply has been un-pinned and flipped over to the interior side of the core assembly, it is then oriented so that the moulded in bullet shapes from FIG. 15 are pointing inward into the interior surface of the core assembly, the wing regions then receive a further sewing from the exterior side of the core assembly to the core assembly,

FIG. 26 shows a local cross-section through the edge of the core assembly, showing the sewing through the core and wing assembly and exterior most fabric ply, the wing region edge is directed toward the cup edge of the core assembly, the body of the wing, directed toward the interior of the cup of the core assembly, the exterior most fabric ply is shown with the bullet shape pointing inward into the interior of the core assembly,

FIG. 27 shows in plan view the sewn assembly of the core assembly, wing regions and exterior most fabric ply, the exterior most fabric ply of the core assembly is then sewed onto the core assembly along the lower perimeter of the core assembly, a further line of stitching is added to attach the exterior most fabric ply to the sewn assembly,

FIG. 28 shows the resultant assembly, formed after the sewing shown in FIG. 27, after being trimmed and sealed at the same time using ultrasonic method, the trimming width covers the stitches so that no stitching remains along the lower perimeter of the assembly, the exterior most fabric ply is still flipped to the interior of the core assembly,

FIG. 29 shows the exterior most fabric ply of the core assembly has been flipped over so that it covers the exterior surface of the core assembly, each of the wing regions is also flipped over so that its free end points away from the core assembly, a small piece of fabric adhesive tape (the same type as that used in FIG. 13A for joining the shoulder strap to the core assembly) is then ironed over the interior side of the core assembly and the wing region at their highest joining point (for reinforcing the attachment of this relatively weak point),

FIG. 30(A) shows the exterior most fabric ply of the core assembly having been re-positioned on the exterior of the core assembly using needles or pins, (B) shows a detailed cross section through the lower perimeter, showing the blind seamless join that is formed,

FIG. 31(A) shows the exterior most fabric ply having been trimmed so that a hem is formed for edge wrapping along the upper perimeter of the bra cup regions of the core assembly and the shoulder straps, adhesive tape is applied to the hem of the exterior most fabric ply, (B) shows a cross-sectional detail showing the exterior most fabric ply, the tape attached there to, and the underlying core assembly,

FIG. 32(A) shows folding of the hem of the exterior most fabric ply about the upper perimeter of the bra cup regions and the shoulder straps, (B) shows a cross-sectional detail showing the exterior most fabric ply, the tape attached there to, and the underlying core assembly, the exterior most ply and tape having been folded onto the interior side of the core assembly and sealed thereto,

FIG. 33 shows the unfinished product after the step described in FIG. 32,

FIG. 34 shows back strap fasteners (i.e. catches and hooks) being positioned onto the free ends of the wing regions by adhesive tape (a single column of two hooks on the left hand wing as looking at the Figure and three columns of two “eyes” each on the right hand wing, the hooks being attached from the interior side by adhesive taping and ironing, the eyes being attached by a similar method from the interior side of the wing and show through cuts in the wing to the exterior surface, a small elongated foam piece is positioned above the hook piece by adhesive tape, the free end of each exterior most fabric ply which extends beyond the back strap fastener is then folded so that it covers the back strap fastener, the hooks being shown through cuts in the folded free end of the exterior most fabric ply to the interior surface, and

FIG. 35 shows finished product in plan view looking at the exterior side.

With reference to FIG. 35 there is shown a bra 54 that may generally be defined by a breast or bra cup region 17, wing regions 30A and 30B as chest bands and shoulder straps 55A and 55B. The shoulder straps 55A and 55B extend between the breast cup regions 17 and each of the wing regions 30A and 30B respectively.

Such over the shoulder straps may however be optional as it is envisaged that the bra may be of a strapless version. Indeed whilst reference is herein made to a bra, it is envisaged that the assembly of panels to define such may alternatively be incorporated into other garments such as, for example, evening dresses or bathing suits or similar.

The construction of the brassiere will now be described.

A core layer or lamination is formed consisting of a fabric layer 1 with foam layer 2 to form an assembly of laminated plies 3. Such assembly may be created in a continuous process to create a long sheet. Alternatively the assembly may be formed as discrete sheets. The lamination is formed by application of heat and pressure to the fabric layer 1 and foam layer 2 by known methods. From the assembly of laminated plies two rectangular pieces 4 are cut. One of these is used to form an exterior layer 5; another is used to form an interior layer. A further piece is cut from the assembly 3, or from another lamination of foam and fabric to form the shoulder strap parts 24. The shoulder strap parts 24 differ in their construction to the interior and exterior layers in that they have, in the preferred embodiment another fabric layer on the other side of the foam, i.e. the layup is fabric, foam, fabric.

The rectangular piece 4 for the exterior layer 5 is then shaped by shaving the foam. The shaping process forms a basic bra shape including a pair of breast cup regions and a bridge region extending between the two bra cup regions. In the preferred embodiment this shaping is to form an apex 6 at around the middle of each bra cup region 17. However in other embodiments there may be no shaping at all, shaping just to reduce the overall thickness of the foam layer, or other forms of shaping in other areas to change the shape and/-or density of that area. In some embodiments the exterior layer 5 may not have a fabric layer at all, the exterior layer of the bra being formed by an exterior most fabric ply 27 (see later).

An underwire structure 7 is formed by wrapping an arcuate metallic underwire 8 within a sock of fabric material 9 closed at both ends by bar-tacking 11. The fabric may also be closed by folding and sewing, heat sealing or similar.

The shaved exterior layer 5 is then located between the upper 12A and lower 12B platens of a moulding machine 12, prior to moulding to impart a three dimensional shape to the exterior layer 5. The platens 12A and 12B are then brought together to apply pressure and in the preferred embodiment, heat, to impart the three dimensional shape to the exterior layer. The resulting layer has the bra cup region 17 now clearly formed.

The foam side of the now moulded exterior layer 19 is then sprayed with adhesive 13 by a spraying machine 15. The adhesive 13 may be any form of adhesive for example heat or chemical (two pot) activated, contact adhesive, self setting or similar. The foam layer 2 side of the exterior layer 19 has an underwire structure 7 positioned (in the preferred embodiment by gluing via the applied adhesive) close to the lower perimeter 16 of each bra cup region 17 on the foam layer 2 of the moulded exterior layer 19. A first bridge layer 18 of flexible fabric material having non-stretch properties is then positioned (in the preferred embodiment by gluing) at the bridge region 56 (i.e. between two bra cup regions 17) on the foam layer 2 of the exterior layer 19. A further or second bridge layer 57 of flexible fabric material (which is only slightly stretchable) has a general “W” shape and is positioned (in the preferred embodiment by gluing) along and over the underwire structures 7, across the bridge region 56 and over first bridging layer 18. Finally a piece of foam layer having a “U” shape 21 is positioned (e.g. by gluing) above the second bridge layer 57 and along and over each underwire structure 7. In alternative embodiments the underwire structures 7 may be coated them selves in adhesive, or may be located to the foam layer 2 of the exterior layer 5 by fusion, for example by ultrasonic techniques, or heat and/or pressure. Additionally this is the preferred lay-up order; in other embodiments the lay-up order may be different.

The interior layer 20 cut out from the assembly of laminated plies 3 shown in FIG. 1, this is then shaved and moulded. The moulding process for the interior layer 20 is the same as that for the exterior layer with the exception that the orientation of the interior layer is reversed. In the interior layer 20 moulding operation the male mould platen 12A locates against the fabric layer 1, the female mould platen 12B locates against the foam layer 2 of the interior layer 20. The interior layer 20 may be shaved and moulded at any time in the process leading up to this point. In the preferred embodiment whilst the moulding machine may be the same as for forming the exterior layer 19, the platens of the machine are different.

The moulded exterior layer 19 and the now moulded interior layer 22 are then located in a moulding machine 12 (whether the same machine as earlier, and in the preferred embodiment this has different platens to those that moulded the interior and exterior layers) to form a core assembly 23 having a proximal face and an opposed distal face and an upper edge or perimeter 48 and a lower edge or perimeter 16. The layer 19 and 22 located so that the foam layer 2 of each respective layer are located against each other.

Pressure and/or heat is then applied to form the lamination of

-   -   the two layers 19 and 22,     -   the underwire structures 7,     -   the layers of fabric material 18 and 57, and     -   the foam pieces 21         along the lower perimeter 16 of each bra cup region 17 and the         bridge region becoming sandwiched between the moulded exterior         layer 19 and the moulded interior layer 22. The resultant core         assembly is then cut from the above sandwich lay-up. This         cutting may be part of the moulding process, either by knives         located in the mould as part of the primary or secondary motion         of the platens. It may also be achieved by a secondary motion of         the platens to shear the unwanted sandwich away. Alternatively         it may be done in an operation away from the mould, e.g. by hand         cutting, or other machining. The core assembly 23 has a bra         exterior 65 (exterior most to the wearer) and a bra interior 64         (interior most to the wearer).

Shoulder strap parts 24 (made from an assembly of pre-laminated plies having a foam layer sandwiched between two fabric layers) are attached to the core assembly 23 by two small pieces of fabric tape 25 having adhesive on one side, one end of the shoulder strap part 24 is attached to the core assembly 23 by wrapping the small piece of fabric tape 25 over the butt or lap joint of the strap end and core assembly. The adhesive of the tape 25 will then melt and provide bonding upon being heated up, e.g. by ironing, or other fusion techniques depending on the adhesive used.

A distal fabric layer or exterior most fabric ply 27 is then preshaped by bullet 28 moulds via a pressure heat forming operation. The shaped exterior most fabric ply 27 is then positioned onto the bra exterior 65 of the core assembly 23 using needles, or pins, 29.

Next will be described the formation of the wing regions 30 that form the chest straps of the brassiere 54.

The exterior most fabric ply 30A of each wing region 30 of the brassiere 54 is cut out from a piece of cloth along the edges of a pre-shaped plastic ruler 35. The interior most fabric ply 30B of each wing region 30 is also cut out from a piece of fabric material. The interior most fabric ply 30B has adhesive 33 (whether activated or to be activated) on one side covered by protective paper 34, a pre-shaped plastic ruler 35 (different to that used for the exterior layer) is used to guide the cutting. The exterior most fabric ply 30A is longer than the interior to provide overlaps to be used later. The exterior most fabric ply 30A is then attached to the interior most fabric ply 30B of the wing portion 30 by sewing along the longest edge of each of these two plies. The adhesive (once exposed) will be between the two plies.

The sewn wing region 30 assembly is then cut along the joined edge of the two plies, so that no stitching remains, and at the same time the two plies are sealed together along a new edge using ultrasonic methods, producing a joined edge 59.

A strip 58 is also prepared (not necessarily at this point of the process, but may be earlier prepared), by fixing of adhesive tape 39 onto a rubber band 40. The strip (having adhesive tape on one side of it) is then fixed, by the adhesive 39 located on it, to the exterior most fabric ply 30A of the wing region 30 along the joined edge 59; the purpose being to reinforce and/or provide elasticity along the joined edge 59.

The exterior most fabric ply 30A and the interior most fabric ply of the wing portion 30B of the wing region 30 are then located between two platens 62A and 62B, and then are laminated together with application of heat and/or pressure, to form the chest strap 60. The resultant laminated plies of the chest straps 60 are then trimmed along the edge of the interior most fabric ply.

The attachment of the exterior most fabric ply 27 and the chest straps 60 to the core assembly 23 will now be described.

Each of the chest straps 60 is located with its edge 63 to be sewn pointing outward (i.e. toward the perimeter 61 of the cup of the core assembly 23). The exterior most fabric ply 27 edge is moved away so as not to be sewn at this point (the exterior most fabric ply, though not shown, is on the other side (the exterior side) of the core assembly 23). The chest straps 60 are then sewn 36 on at a securing zone. This is easiest done with the core assembly's bra interior 64 facing upward, though other ways are also possible.

The assembly (chest strap 60, core assembly 23 and exterior most fabric ply 27) is then turned over to have the bra exterior 65 showing. The exterior most fabric ply 27 is un-pinned and flipped over to the interior side of the core assembly 23, it is then oriented so that the moulded-in bullet shapes from FIG. 15 are pointing into the bra interior 64 of the core assembly 23. The wing regions then receive a further sewing from the exterior side of the core assembly to the core assembly The exterior most fabric ply 27 of the core assembly 23 is then further sewn onto the core assembly 23 along the lower perimeter 16 of the core assembly 23, by a further line of stitching added to attach the exterior most fabric ply.

The result is sewing through the core assembly 23 and chest strap 60 and exterior most fabric ply 27. The chest strap edge 63 is directed toward the perimeter 61 of the core assembly 23. The body of the chest strap 60 is directed toward the bra interior 64. The exterior most fabric ply 27 is shown with the bullet shape pointing into the bra interior 64 of the core assembly 23.

The resultant assembly is then trimmed and sealed at the same time using the ultrasonic method. The trimming width covers the sewing 36 so that no stitching remains along the lower perimeter 16 of the assembly. The exterior most fabric ply 27 is still flipped to the bra interior 64 of the core assembly 23.

Each of the chest straps 60 is then flipped outward so that its free end points away from the core assembly 23, a small piece of fabric adhesive tape 25 is then ironed over the interior side of the core assembly 23 and the chest strap at their highest joining point. This reinforces the attachment at this relatively weak point. The tape 25 can be the same as that used for attaching the strap parts 24 and may be adhered using similar methods.

The exterior most fabric ply 27 is then re-positioned on the bra exterior 65 of the core assembly using needles or pins. This is achieved by folding it over the lower perimeter 16 so that covers the raw edge of the sealed and trimmed lower edge and is relocated back onto the bra exterior 65 surface. The folding of the exterior most fabric ply 27 over the lower perimeter will create a distal flap where the edge of the exterior most fabric ply 27 is sewn onto the core assembly 23. The resulting seamless blind join 67 is then formed on the bra interior 64. In the preferred embodiment this seamless blind join 67 is located just “up” from the lower perimeter 16. However in other embodiments it may be on the lower perimeter 16 itself, or further up the “height” of the bra interior 64. In one embodiment, the exterior most fabric ply 27 will cover the securing zone where the wings are sewn onto the core assembly 23, thereby increasing comfort levels of a person wearing the brassiere.

The exterior most fabric ply 27 is then trimmed so that a hem 66 is formed. The hem 66 is for edge wrapping along the upper remaining perimeter 48 of the bra cup regions 17 of the core assembly 23 and the shoulder straps 55 (or at least part thereof. Adhesive tape 39 is applied to the hem 66 of the exterior most fabric ply 27.

The hem of the exterior most fabric ply 27 is then folded about the upper perimeter 48 of the bra cup regions 17 and the shoulder straps—, FIG. 32(B) shows a cross-sectional detail showing the exterior most fabric ply, and the tape is sealed to the fabric layer 1 of the moulded interior layer 22 of the core assembly 23.

Thereafter back strap fasteners (i.e. eyes 52 and hooks 51) are positioned onto the free ends of the chest straps 60 by adhesive tape 39. A single column of two hooks 51 on the left chest strap 60 as looking at FIG. 34 and three columns of two “eyes” 52 each on the right chest strap 60. The hooks 51 are attached from the interior side of the chest strap 60 by adhesive taping and ironing. The eyes 52 are attached by a similar method from the interior side of the chest strap and show through cuts 53 in the chest strap to the exterior surface. A small elongated foam piece is positioned above the hook piece by adhesive tape. The free end of each exterior most fabric ply 27 which extends beyond the back strap fastener is then folded so that it covers the back strap fastener. The hooks are shown through cuts in the folded free end of the exterior most fabric ply to the interior surface. Each shoulder strap is then extended by connecting an extra piece thereto by an ultrasonic method such as ultrasonic welding. The finished product is shown in plan view looking at the exterior side in FIG. 35.

At the ends of each of the chest bands 60 the hooks 51 and eyes 52 for the hooks that are mutually cooperative to allow for the bra to be fastened about the chest of a wearer.

The bra may be seamless and made from materials at least some of which are moulded or mouldable and that are engaged to each other preferably at least in part by lamination. In other embodiments the brassiere 54 may have no shoulder straps, or the seamless edge may be incorporated into garments other than a bra, but nevertheless perform a similar function.

The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention. 

1. A moulded brassiere, including a core assembly of at least a first layer of moulded foam material preferably laminated with a second layer of moulded foam material, said core assembly defining two breast cup regions and an intermediate bridge region extending there between, and wherein at least one layer of flexible material having non-stretch properties is provided adjacent one of or intermediate of and laminated with said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable; and a first and second layer, each of at least a fabric material, is disposed outside of and each laminated with said core assembly on a respective interior and exterior side of said core assembly to preferably encase said core assembly, and a third layer joined at least to said first layer at or near the lower most perimeter of said core assembly, said third layer wrapped over the lower most perimeter and extending to or towards the remaining perimeter of said core assembly.
 2. A moulded brassiere including, a core assembly of at least a first layer of moulded foam material preferably laminated with a second layer of moulded foam material, said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein at least one layer of flexible material having non-stretch properties is provided adjacent one of or intermediate of and laminated with said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable, and a first and second layer, each of at least a fabric material, disposed outside of said core assembly on the respective interior and exterior sides of said core assembly, said first layer laminated to the interior side of said core assembly, said second layer joined at its lower edge at the lower perimeter of the core assembly, to said first layer and folded over to wrap around said core assembly to the exterior side of said core assembly, the join between said first and second exterior layers located toward the bottom periphery of said moulded brassiere, having no raw edges or sewing presenting exteriorly.
 3. A moulded brassiere according to claim 1, wherein there is an intermediate fabric layer between said core assembly and at least one of said first and second layers of fabric that is/are laminated with said core assembly.
 4. A moulded brassiere according to claim 1, wherein said flexible material having non stretch properties is a woven fabric material with bi-directional non-stretch properties and is oriented such that the non stretch orientation extends across said bridge region parallel to the cup to cup direction of said core assembly.
 5. A moulded brassiere according to claim 1, wherein said layer of flexible material having non stretch properties is captured intermediate of said first and second layer of moulded foam material.
 6. A moulded brassiere according to claim 1, wherein said first and second layers of foam are coextensive with each other and both define the perimeter of the said core assembly.
 7. A moulded brassiere according to claim 1, wherein said core assembly is of a shape defining only the breast cups, said bridge and preferably at least in part said shoulder straps, but not chest strap(s).
 8. A moulded brassiere according to claim 7, wherein said chest straps extend outwardly from each side of said core assembly provided region of said moulded brassiere.
 9. A moulded brassiere according to claim 1, wherein two underwire structures are provided intermediate of said first layer and said second layers of foam, one each adjacent the breast cup regions.
 10. A moulded brassiere according to claim 1, wherein said first layer and said second layer of foam are laminated directly to each other save for said flexible material having non-stretch properties and said two underwire structures.
 11. A moulded brassiere according to claim 9, wherein said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member.
 12. A moulded brassiere according to claim 11, wherein said casing is a fabric material.
 13. A moulded brassiere according to claim 11, wherein said casing is adhered to one or each of the facing surfaces of said first and second layers of foam by an adhesive material.
 14. A moulded brassiere according to claim 1, wherein said casing is a tubular sock within which said rigid elongate member is located, the sock having closed distal ends.
 15. A moulded brassiere according to claim 1, wherein said first layer and said foam layer or the foam layers are coextensive each other.
 16. A moulded brassiere according to claim 1, wherein said second layer and said foam layer or the foam layers are coextensive each other.
 17. A moulded brassiere including, a core assembly of at least a first layer of moulded foam material said core assembly defining at least one breast cup region and a first and second layer, each of at least a fabric material, disposed outside of said core assembly on the respective interior and exterior sides of said core assembly, said first layer laminated to the interior side of said core assembly, said second layer joined at the interior side of core assembly at its lower edge at the lower perimeter of the core assembly to said core assembly (and preferably to the first layer) and folded over to wrap around said core assembly to the exterior side of core assembly.
 18. A method of manufacturing a moulded component assembly for a brassiere comprising or including: affixing to a core of at least a first layer of moulded foam material (and preferably a second layer of foam material) and preferably with which and/or between which there is sandwiched a layer of flexible material having non stretch properties, a layer of fabric material at the inner side of the core and adjacent the lower perimeter of the core, wrapping the layer of fabric material around at least part of the lower perimeter to the exterior of the core and affixing the layer to at least part of other perimeter regions of the core.
 19. A moulded brassiere, including a core assembly having a proximal face and an opposed distal face, said core assembly comprising a core layer defining two breast cup regions, and at least one upper edge and at least one lower edge, and a bridge region extending between the breast cup regions; a distal fabric layer, defining an upper edge and a lower edge, said distal fabric layer extending from the distal face of the core assembly around at least part of the lower edge of the core assembly to the proximal face of the core assembly, said distal fabric layer being folded over distally along its lower edge to form a distal flap, said distal flap being secured to the proximal face of the core assembly.
 20. A moulded brassiere according to claim 19, wherein distal fabric layer is comprised of at least one layer of moulded foam and at least one layer of fabric.
 21. A moulded brassiere according to claim 19, wherein the core layer is composed of at least one layer of moulded foam and at least one layer of fabric.
 22. A moulded brassiere according to claim 19, wherein the distal fabric layer extends from the distal flap, around the lower edge of the core assembly, across at least part of the distal face of the core assembly, and around the upper edge of the core assembly, to the proximal face of the core assembly.
 23. A moulded brassiere according to claim 19, wherein the distal fabric layer is secured along its upper edge towards the upper edge of the proximal face of the core assembly.
 24. A moulded brassiere according to claim 19, wherein the distal flap is secured to the proximal face of the core assembly towards the lower edge of the core assembly.
 25. A moulded brassiere according to claim 24, wherein the distal flap is secured to the proximal face of the core assembly towards the lower edge of the core assembly by means of ultrasonic welding.
 26. A moulded brassiere according to claim 23, wherein the distal fabric layer is secured to the proximal face of the core assembly towards the upper edge of the core assembly by adhesive bonding.
 27. A moulded brassiere according to claim 23, wherein the distal fabric layer is secured to the proximal face of the core assembly towards the upper edge of the core assembly by ultrasonic welding.
 28. A moulded brassiere according to claim 19, wherein the core assembly includes an underwire structure comprising at least one resiliently rigid arcuate elongate member.
 29. A moulded brassiere according to claim 28, wherein the underwire structure is secured to the distal face of the core layer.
 30. A moulded brassiere according to claim 28, wherein the underwire structure further comprises a sock surrounding the elongate member.
 31. A moulded brassiere according to claim 19, wherein the core assembly includes a chest strap member secured to the core layer outwardly of each breast cup region.
 32. A moulded brassiere according to claim 31, wherein the chest strap member is secured to the core layer at a securing zone.
 33. A moulded brassiere according to claim 31, wherein each of the chest strap members is secured to the core layer by sewing.
 34. A moulded brassiere according to claim 31, wherein each of the chest strap members is secured to the core layer by ultrasonic bonding.
 35. A moulded brassiere according to claim 31, wherein each chest strap comprises at least a pair of ultrasonically bonded fabric layers each having an upper and lower edge.
 36. A moulded brassiere according to claim 35, wherein the fabric layers of the chest strap are coextensive of each other and are bonded to each other towards their lower edges.
 37. A moulded brassiere according to claim 36, wherein the lower edge of each of the pair of fabric layers of the chest strap are folded in towards each other and bonded at their adjacent faces.
 38. A moulded brassiere according to claim 31, wherein each chest strap includes a resilient elongate strap.
 39. A moulded brassiere according to claim 38, wherein the resilient elongate strap is composed of natural or synthetic rubber.
 40. A moulded brassiere according to claim 19, wherein the core assembly includes a shoulder strap secured to the core layer towards its upper edge above each breast cup region.
 41. A moulded brassiere according to claim 19, wherein the distal fabric layer overlaps at least one of the securing zones where it extends from the proximal face of the core layer to the distal face of the core layer. 